Moulding of concrete walls

ABSTRACT

A method and apparatus for moulding concrete walls and for forming a mould assembly for moulding concrete walls using a pair of spaced moulds ( 11 ) formed by a plurality of mould panels ( 12 ) and ( 13 ) which have peripheral portions which overlap. Interconnecting pins ( 28 ) extend between the moulds ( 11 ) passing through the overlapping portions of the panels ( 12 ) and ( 13 ) to interconnect at least adjacent side by side mould panels ( 12 ) and ( 13 ) and space the moulds ( 11 ) from each other. Supporting frames ( 48 ), ( 49 ) or ( 60 ) form a supporting grid to support the moulds ( 11 ) at least at one side in an upright attitude.

TECHNICAL FIELD

[0001] This invention relates to a method and apparatus for theconstruction of walls from a settable material such as concrete.

BACKGROUND ART

[0002] Solid walls of building can be constructed using a number ofmethods with one common method being the use of bricks for forming abrick veneer wall. Walls constructed in this manner are relativelyexpensive and time consuming to construct. Where solid concrete wallsare constructed, concrete formwork is custom made to suit the particularwall to be constructed. This formwork is only used once and is veryexpensive, resulting in an expensive end product.

SUMMARY OF THE INVENTION

[0003] The present invention aims to provide an improved method andapparatus for constructing walls of concrete or other settable materialand in particular an improved method and apparatus which enables wallsto be constructed efficiently and with reduced costs as compared tocurrent construction costs.

[0004] The present invention thus provides in one aspect, a method ofconstructing a wall of concrete or other settable material, said methodincluding the steps of

[0005] providing first and second moulds, each said mould comprising aplurality of mould panels, each said mould panel having a mouldingsurface,

[0006] arranging said mould panels relative to each other such thatperipheral portions of adjacent said mould panels overlap and saidmoulding surfaces are substantially coplanar to define mould faces ofsaid first and second moulds,

[0007] providing interconnecting means for holding said moulds at adesired spacing to define a mould cavity therebetween, saidinterconnecting means extending through said overlapping portions ofsaid mould panels to interconnect at least adjacent side by side mouldpanels in each said mould,

[0008] depositing concrete or other settable material into said mouldcavity to form said wall, and

[0009] removing said moulds after curing of said concrete or settablematerial.

[0010] In another aspect, the present invention provides a method oferecting a mould assembly for constructing a wall of concrete or othersettable material, said method including the steps of providing firstand second moulds, each said mould comprising a plurality of mouldpanels, each said mould panel having a moulding surface,

[0011] arranging said mould panels relative to each other such thatperipheral portions of adjacent said mould panels overlap and saidmoulding surfaces are substantially coplanar to define mould faces ofsaid first and second moulds,

[0012] providing interconnecting means for holding said moulds at adesired spacing to define a mould cavity therebetween, saidinterconnecting means extending through said overlapping portions ofsaid mould panels to interconnect at least adjacent side by side mouldpanels in each said mould.

[0013] Preferably, the moulds and mould panels in each mould areinterconnected in such a manner as to prevent movement of said facestransversely away from each other but permitting limited movement of thepanels longitudinally relative to each other. Mould panels of each mouldare usually arranged both in a horizontal end-to-end relationship aswell as panels one above the other in a vertical relationship and theinterconnecting means may also interconnect panels either directly orindirectly in a vertical relationship to prevent their verticalseparation. Panels vertically are suitably aligned one above the other.

[0014] The methods may include the step of providing flexible or elasticmeans between mating ends of adjacent panels to accommodate limitedlongitudinal movement of the panels relative to each other where themould panels are formed of a material with high thermal expansionproperties. The flexible or elastic means also forms a seal betweenadjacent panels. Where mould panels formed of low thermal expansivematerials are used, such flexible or elastic means may not be required.Typically, a wall constructed using the methods of the invention isformed upon an existing floor defined for example by a concrete slab andan impervious membrane or layer may be provided between the floor andmoulds to permit the constructed wall to move relative to the slab.Preferably, the method of construction includes the step of providingreinforcing between the moulds prior to depositing of the concrete orsettable material. The reinforcing may be connected to the floor in sucha manner as to allow limited movement of the reinforcing relative to thefloor with movement of the wall.

[0015] Preferably, the interconnecting means comprise elongatedconnectors and the panels include in their peripheral portions,apertures which are aligned with each other when the peripheral portionsoverlap, and the method includes the step of passing opposite ends ofthe elongated connectors through the aligned apertures to interconnectthe panels and moulds. The method of construction also may include thestep of providing flexible or elastic elements for example in the formof bushes in at least some of the apertures to receive the ends of theconnectors and allow limited movement of the panels relative to theconnectors. The method of construction may also include the step ofremoving the ends of the elongated connectors after curing of theconcrete or other settable material.

[0016] The present invention in a further aspect provides apparatus forforming walls of concrete or other settable material, said apparatusincluding first and second moulds, each said mould having a mould facedefined by a plurality of mould panels, each said mould panel having amoulding surface, the peripheral portions of adjacent said mould panelsoverlapping each other and said moulding surfaces being substantiallycoplanar to define mould faces of said first and second moulds, andinterconnecting means holding said moulds at a desired spacing to definea mould cavity therebetween, said interconnecting means extendingthrough said overlapping peripheral portions of said mould panels tointerconnect at least adjacent side by side said mould panels

[0017] Preferably, the interconnecting means permits limited movement ofthe mould panels relative to each other in a longitudinally directionrelative to each other.

[0018] Preferably the moulds are supported in an upright position by asupport frame or post. Suitably, a plurality of support frames or postsare provided and adjacent support frames or posts are interconnected byelongated spanning members. The spanning members set the length of thepanels so as to be the same as the reinforcing within the panels.

[0019] The mould panels in one form may be of a rectangular planarconfiguration are preferably provided with a plurality of apertures intheir peripheral portions for cooperation with the interconnectingmeans. Apertures are at least provided at or adjacent the cornersthereof. Apertures may also be provided along the upper and lower edgesof the panels and suitably centrally of the panels. The interconnectingmeans suitably comprise in one form elongated connectors which extendinto selected aligned apertures in mould panels in the first and secondmoulds. Preferably, the elongated connectors are provided with flangeswhich abut the mould surfaces of the panels to set the spacing betweenthe moulds. Preferably, the elongated connectors have spigot-like endswhich extend through the panel apertures (and support frames or postswhere used) and stop means are engageable with the ends to hold thepanels (and support frames or posts where used) to the elongatedconnectors. Preferably the stop means are spaced from the flanges adistance such as to allow the longitudinal movement of the mould panels.Preferably, the ends adjacent the flanges are of an enlarged diameter toform bosses for receipt in the panel apertures, the bosses being of alength slightly greater the width of a pair of joined panels at theapertures. Preferably, the ends are separable from the remainder of theelongated connectors. The ends are preferably separable at the flangesto leave a surface substantially flush with the outer surface of thewall being moulded. Preferably, the connection between the spigot-likeends and remainder of the elongated connectors is necked adjacent theflanges to so that the ends of the elongated connectors may be easilybroken off by twisting. For this purpose, the ends of the elongatedconnectors may be shaped for engagement by a suitably tool such as awrench which can be used to twist off the ends of the elongatedconnectors. Preferably, the ends of the elongated connectors have one ormore flats and the socket has a corresponding cross section for neatreceipt of the end whereby the tool may be twisted by gripping of thehandle to effect breaking off of the end.

[0020] In an alternative configuration, the ends of the elongatedconnectors may be threaded and the stop means comprise nuts which may bethreadably engaged with the threaded ends of the elongated connectors.

[0021] Preferably, the ends of the elongated connectors include at leastone slot for receiving a stop member therethrough defining the stopmeans which secures the elongated connectors to the panels and/orsupport frames and posts. Preferably, the stop member is of a taperingor wedge-shaped configuration such that it may be wedged into the slot.Preferably a pair of spaced slots are provided in one or both ends suchthat the stop member can be placed in different positions in the enddepending upon whether the connectors pass through a support frame/post.

[0022] In another arrangement, the elongated connectors may be in atleast two parts comprising an outer sleeve part having shoulders orflanges at each end which are arranged in use to abut the inner mouldfaces. The other part comprises an elongated pin which is receivable inthe sleeve part, the opposite ends of the pin extending outwardly atopposite ends of the sleeve part to define spigot-like ends. The pin maybe held within the sleeve part by an interference fit. The spigot-likeends may be of similar configuration to the previously mentioned spigotends being provided with slots therein to accept stop members orprovided with threads to accept threaded nuts which serve as stopmembers to retain the mould panels (and support frames where used) tothe pins. The pin may also be provided in two parts comprising an innerpin member having one or more slots or threads at each end and an outertubular sleeve member surrounding the inner pin member and aninterference fit therewith. The outer tubular sleeve member suitably isof a length greater than the outer sleeve part such that projecting endsof the sleeve member defining the bosses for location in the aperturesin the panels.

[0023] After moulding, the stop members or nuts are removed permittingthe pins to be withdrawn from the outer sleeve parts leaving the outersleeve parts within the formed wall. Ends of the sleeve part may beplugged by suitable bungs.

[0024] Most preferably, the apertures in the panels which receive theends of the elongated connectors are of a greater diametrical dimensionthan the ends of the elongated connectors and may be formed to accept aflexible bush or insert into which the ends project such as tocentralize the elongated connectors within the apertures and allowexpansion movement of the panels. The flexible bushes or inserts areused where required to allow for movement of the panels which may resultfrom exposure of the mould panels to the sun, the mould panels having anexpansion rate substantially greater than the expansion rate of a floorslab or other foundation upon which the wall is moulded. The flexiblebushes or inserts also serve as a seal to prevent escape of the settablematerial around the pins.

[0025] The panels suitably are of two configurations to enable joiningthereof and for forming a substantially planar mould face. In onearrangement, the panels are suitably recessed around their perimeter todefine in each panel a peripheral flange and the panels are arranged inan opposing relationship and flanges mate with each other to form themoulds. In this configuration, the peripheral flanges of the panels areprovided with the apertures which can align when the flanges mate witheach other. Preferably, the respective corners of the panels aretruncated at 45 degrees to allow cooperation diametrically with adjacentpanels. The panels rearwardly of their mould surfaces are preferablyreinforced to provide sufficient stiffness to the mould surfaces toprevent deformation thereof during moulding. Preferably, the reinforcingis formed by a plurality of intersecting webs. The flanges may also beprovided with reinforcing webs as in the panels with bosses formedaround the apertures in the flanges. The panels are suitably formed ofplastics, glass reinforced plastics, or any other suitable material suchas timber or a timber moulding.

[0026] In a further form, the mould panels may be of a curvedconfiguration to enable the construction for example of curved walls forexample for the construction of tanks of circular configuration or anyother curved structure. The mould panels in other respects are aperturedin a similar manner to the planar panels and may be interconnected inthe same manner as described above.

[0027] In construction of a wall, suitable reinforcing is providedbetween the moulds prior to pouring of the concrete or other settablematerial. Preferably, the reinforcing includes a plurality of verticalreinforcing members and a plurality of horizontal reinforcing members.The vertical reinforcing members may be secured to upwardly projectingstarter bars around which resilient sleeves may be provided to allow forindependent expansion movement of the wall. Where the wall is to beerected on a slab, the slab may be provided with a plurality of starterbars which project upwardly out of the slab and the vertical reinforcingmembers may be attached to the starter bars. The vertical reinforcingmembers may be wired to the starter bars or may be connected through athreaded connection to the starter bars.

[0028] In an alternative arrangement, the floor slab may be providedwith reinforcing mounts to which the vertical reinforcing members may beattached, the mounts allowing limited movement of wall relative to thefloor slab. The mounts may comprise a base member which is anchored inthe slab and a coupling member which is supported for limited horizontaland vertical movement relative to the base member. Preferably, thecoupling member includes a coupling plate carrying a socket forengagement by a vertical reinforcing member and the base member capturesthe plate. Most preferably, the base member includes first and secondplates located above and below the coupling plate. The socket suitablyprojects above the slab and a cover seals the socket to the base memberto prevent ingress of concrete into the mount. Preferably also means areprovided between the coupling plate and base member to facilitatesliding movement of the coupling plate relative to the base member andalso allow the mount to be installed out of square. Resilient pads mayalso be provided to limit movement of the coupling plate.

[0029] Whilst the reinforcing mounts are particularly suited to thepresent application, it will be appreciated that they also may be usedin the construction of walls of other configuration and used in otherapplications such as earthquake applications to allow limited movementof a wall relative to a floor such as a floor slab and absorb energy.

[0030] Both the mounts and resilient sleeves are suitably used incombination with a membrane or layer which is applied to a floor such asa slab floor prior to pouring of the concrete or other settablematerial. This will allow for expansion or other movement of the wallrelative to the floor.

[0031] Where the walls are moulded in areas not frequently subject toearthquakes, walls may be moulded directly onto the slab without the useof a membrane between the wall and slab or the use of resilient sleevesor the reinforcing mounts. Building standards and codes in these areasgenerally do not require the use of such components.

[0032] For erection of an internal wall on a slab where no starter barsor reinforcing is used to prevent the mould panels riding upwardlyduring moulding, mould panels may be assembled as described above todefine a pair of moulds and clamping means may be provided to clamp themoulds to the floor upon which the wall is to be erected. The clampingmeans may comprise clamp rods located on opposite sides of the mouldsand engage with a clamp member located on top of the moulds. The clampmember may comprise flexible pads to prevent the moulds from beingdamaged. At their lower ends, the clamp rods may engage with bracketssecured to the floor. The brackets may extend beneath the moulds.Projecting ends of the brackets on either side of the constructed wallmay be severed after removal of the moulds. Internal walls may beconstructed with a reinforced concrete such as fibre reinforced concretethereby eliminating the need to use steel reinforcing. If desiredhowever steel reinforcing can be used and internal walls can beconstructed over starter bars.

[0033] Door openings may be formed in walls during the moulding processby the placement of door frames between the opposite moulds to engagethe mould faces such that during construction of the wall, the concreteor other settable material only fills the mould cavity up to the doorframe. In some cases, mould panels within the door frame opening may beremoved or not included when the moulds are assembled. Where dooropenings are formed in a wall, a reinforcing link may be provided in thefloor slab beneath the opening to prevent cracking around the opening inthe event that movement occurs between the wall and slab. Thereinforcing link may be located within a trench in the floor slab andtied off at each end to the reinforcing within the mould cavity prior toformation of the wall. The trench may be covered by suitable coverplates.

[0034] For longer wall lengths, expansion joints may be needed to beincorporated into the moulds to separate the moulds into mould sections.The expansion joints suitably include first and second complementary endmembers which are secured to adjacent mould sections. The complementaryend members may include co-operable configurations such as aprotuberance which locate within a complementary recess to maintainlongitudinal alignment of the mould sections. Resiliently compressiblemeans may be provided between the complementary end members. The endmembers may be secured to the inside of the mould panels of the mouldsto be retained after moulding of the wall section on each side of theexpansion joint or alternatively, the end members may be secured to theoutside of the mould panels to be detachable after moulding of the wallsections.

[0035] Means may be provided to limit longitudinal movement of the wallsections on opposite sides of an expansion joint away from each other.Such means may include one or more links fixed to the adjacent wallsections by suitably fixing anchors passed through apertures in thelinks. One of the apertures may be of elongated form to accommodatelimited movement of the wall sections.

[0036] For defining a buttress wall, an end member of similar overallconfiguration of the end members for the expansion joint but having aplanar end face may be employed, being secured to the ends of a mouldsduring the moulding process.

[0037] Corners in a wall may be manufactured by means of angled cornerpanels usually of right-angled configuration joined to the spaced mouldsdefining the wall. The corner panels may be joined to the moulds bybridging members joined to the panels and corner panels by the elongatedconnecting members.

[0038] T-junctions may be established similarly by means of panelsdefining a T-shape and comprising a first planar rear panel and a pairof opposed angle panels of right-angled configuration. The rear panelmay be placed in alignment with the mould panels of one wall mould andjoined thereto whilst the pair of angle panels is joined to the mouldpanels of the other wall forming mould and to other moulds defined byjoined mould panels to defining a walls extending at right angles toeach other. The panels defining the T-junctions are suitably joined tothe mould panels of the walls by bridging members and the elongatedconnecting members.

[0039] For forming or defining window openings within a wall formed bythe mould panels, a pair of spaced apart aligned frames are providedadjacent opposite moulds surrounding the desired window opening. Infillpanels may be provided between opposite frames and fit over the mouldpanels to define the window opening, concrete or other settable materialfilling the cavity between the moulds up to the infill panels duringformation of the wall, the panels and the frames being removed afterformation of the wall to leave the window opening within the wall. In analternative arrangement for forming or defining window openings, arectangular frame may be located in the cavity between the moulds, theframe extending between the opposite moulds. The lower frame member ofthe frame which defines or is adjacent the window sill may be providedwith one or more holes to enable depositing of concrete beneath theframe member. Cover plates may be attached to the frame member over theholes to seal the holes and permit continued moulding of the wall. Thecover plates may be provided with removable blanking plates which fitwithin the holes. The cover plates may be removed leaving the blankingplates within the holes after moulding. The frames may be collapsible toenable them to be removed from the wall after moulding or may remain insitu within the moulded wall.

[0040] The formwork mould panels are reused where possible and areproduced by processes enabling mass production to reduce costs. Labourcontent using the system in erection of walls is also less than currentmethods and recycled or recycleable plastics or other materials may beused wherever possible in the moulding system components. The finishedconcrete walls require no pest treatment thus saving possible termitedamage as encountered in timber structures.

[0041] Different means other than that described may be provided formounting the walls to the floor slab and where the reinforcing mountsare used, different flexible components may be used within the mounts.Window openings may either be moulded plain or with a rebate to locatewindows. All components may be made of any suitable material or made byany suitable method. Different shapes may also be moulded into the wallsformed using the method and apparatus of the invention by the use ofsuitably shaped moulding members or inserts between the moulds. Forexample, angled inserts may be used to define gables or curved insertsprovided to define arches.

[0042] In yet a further aspect the present invention provides a methodof erecting a mould assembly for constructing a wall of concrete orother settable material, said method including the steps of arranging atleast one pair of mould panels in a desired spacing to define a mouldcavity therebetween, said mould panels having apertures therein, theapertures in the respective mould panels being transversely aligned witheach other, providing flexible elements within said apertures, providinginterconnecting means between said mould panels for holding said mouldpanels at said desired spacing, said interconnecting means extendingthrough said flexible elements and apertures in said spaced mouldpanels, whereby to permit limited longitudinal movement of said mouldpanels relative to said interconnecting means.

[0043] Preferably, the method includes the step of arranging a pluralityof mould panels in an edge-to-edge mating relationship and providingflexible or elastic means between mating edges of the mould panels toaccommodate said limited longitudinal movement thereof. The methodpreferably also includes the steps of providing a plurality of uprightsupport means for supporting said mould panels in an upright attitude,and securing the interconnecting means to the support means on at leastone side of said mould panels. The method also may include the step ofproviding elongated spanning members for spanning and interconnectingthe upright support means to form a support grid for the panels.

[0044] The present invention in yet a further aspect provides aconnector pin assembly for connecting a pair of spaced apart mouldpanels defining a mould cavity therebetween, said mould panels beingprovided with transversly aligned apertures, said connector pin assemblycomprising a pin having opposite ends receivable in said panelapertures, and a spacing member surrounding said pin and adapted to abutinner opposite faces of said panels to space the panels from each other.Preferably, the spacing member is a sleeve-like member which may be aninterference fit with the pin and having shoulders or flanges at eachend for abutting the faces of the panels. The pin may also be providedin two parts comprising an inner pin member and an outer tubular sleeve.Opposite ends of the pin or pin member are suitably adapted to beengaged by stops to retain the panels to the pin or pin member. For thispurpose, the pin or pin member may be provided with one or more slots ateach end to receive retaining wedge members. Alternatively, the ends ofthe pin of pin member may be threaded for receipt of threaded retainers.

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] In order that the invention may be more readily understood andput into practical effect, reference will now be made to theaccompanying drawings which illustrate a preferred embodiment of theinvention and wherein:

[0046]FIG. 1 illustrates schematically in exploded view the mouldingmethod and apparatus according to the invention;

[0047] FIGS. 2(a) and (b) illustrate in side and end views, one form ofmould panel for use in the method and apparatus of the invention;

[0048] FIGS. 3(a) and (b) illustrate in side and end views a second formof mould panel which is complementary to the panel of FIG. 2 shown inopposite views to the views of FIGS. 2(a) and (b);

[0049] FIGS. 4 (a) and (b) illustrate portion of a modified form ofpanel;

[0050]FIG. 5 illustrates the manner in which mould panels interlock;

[0051]FIG. 6 is a sectional view along line A-A of FIG. 5;

[0052]FIG. 7 is a sectional view illustrating the manner in which thepanels are interconnected by connecting pins;

[0053]FIG. 8 illustrates a connecting pin for interconnecting the panelsin the direction B of FIG. 7;

[0054]FIG. 9 is an end view of the connecting pin;

[0055]FIG. 10 is an enlarged view of the region C of FIG. 7;

[0056] FIGS. 11 (a) and (b) illustrate in plan and elevational views, abreak-off tool for use with the connecting pins;

[0057]FIG. 12 illustrates the end of an alternative connecting pin;

[0058]FIG. 13 illustrates a nut for use with the pin of FIG. 12;

[0059]FIGS. 14, 15 and 16 illustrate in side view, alternative supportframes for the mould panels;

[0060]FIG. 17 illustrates in enlarged sectional view a typical levelingscrew for use with the support frames of FIGS. 14 and 15;

[0061]FIG. 18 illustrates the typical configuration of reinforcingbetween the moulds and methods of flexibly connecting reinforcing forthe walls to a floor slab;

[0062]FIG. 19 is a side view of the assembled panels, starter barconfigurations and resilient sleeves;

[0063]FIGS. 20 and 21 illustrate in sectional and plan view a slidingmount for the reinforcing for the walls;

[0064]FIG. 22 illustrates the lower end of a mould raised above a floor;

[0065]FIG. 23 illustrates an infill panel for use between the mouldpanels and floor;

[0066]FIGS. 24 and 25 illustrate in cross sectional and plan view, ahold down arrangement for the panels for construction of an internalwall where no starter bars or reinforcing is used; and

[0067]FIG. 26 illustrates an alternative hold down arrangement for thepanels.

[0068]FIG. 27 illustrates the manner in which door frames may beinstalled during construction of a wall according to the presentinvention;

[0069]FIG. 28 illustrates a subfloor link arrangement for use beneathdoor openings;

[0070]FIG. 29 is an enlarged view of the region D of FIG. 28;

[0071]FIG. 30 illustrates in plan view an arrangement for incorporatingan expansion joint into walls during the moulding thereof;

[0072] FIGS. 31(a) and (b) illustrate the end connectors for use in theexpansion joint;

[0073]FIG. 32 illustrates in plan view an alternative configuration ofexpansion joint;

[0074]FIG. 33 illustrates expansion joint limiters at the expansionjoint between wall sections;

[0075]FIG. 34 illustrates the method of forming a buttress wall;

[0076]FIG. 35 illustrates in plan view a corner configuration;

[0077]FIG. 36 illustrates in isometric view a corner connector;

[0078]FIG. 37 illustrates in plan view a T-junction configuration;

[0079]FIG. 38 illustrates in isometric view a T-junction connector;

[0080]FIG. 39 illustrates in elevational view a bridging plate forconnection wall panels to the connectors of FIGS. 36 and 38;

[0081]FIGS. 40 and 41 illustrate in side and plan views, apparatus fordefining a window within a wall being moulded;

[0082]FIG. 42 is an exploded view showing the components of the windowdefining frame assembly of FIGS. 40 and 41;

[0083]FIG. 43 illustrates in plan view an alternative window mouldpanel;

[0084]FIG. 44 is a view in the direction E of FIG. 43;

[0085]FIG. 45 illustrates in side view alternative side panels for thewindow moulds;

[0086]FIG. 46 illustrates the panel configuration at a corner of thewindow defining frame assembly;

[0087]FIG. 47 and 48 illustrate in side and isometric view, the panelsat a window corner moved apart;

[0088]FIG. 49 illustrates a conduit at a slab junction;

[0089]FIG. 50 illustrates in part sectional view, an alternativeconnection pin assembly for connecting moulds and mould panels;

[0090]FIG. 51 illustrates in longitudinal sectional view, the sleeve ofthe connection pin assembly of FIG. 50 and associated end plugs;

[0091]FIG. 52 is an end view of the sleeve of FIG. 51;

[0092]FIG. 53 illustrates in side view a window defining frame locatedin a mould cavity between moulds;

[0093]FIG. 54 is a view of the frame in the direction G of FIG. 53;

[0094]FIG. 55 illustrates the manner in which a gable can beconstructed;

[0095]FIG. 56 illustrates in exploded view an alternative method forsupporting and erecting mould panels for constructing a wall formingmould; and

[0096]FIG. 57 is a part sectional view showing the assembly of mouldpanels of the method of FIG. 56.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0097] Referring to the drawings and firstly to FIG. 1, there isillustrated schematically apparatus 10 for erecting walls according tothe invention. The apparatus 10 includes a pair of opposite moulds 11,each defined by a plurality of interconnected mould panels 12 and 13,the interconnected panels 12 and 13 defining planar moulding faces 14 ofthe moulds 11. The moulding faces 14 however may be textured to create atextured face in the erected wall. The panels 12 as shown in FIG. 2 arein this embodiment of a generally rectangular configuration and suitablyare moulded from glass filled plastic but may be made by any means orfrom any suitable material. Panels 12 and 13 are configured to interlockwith each other in an end-to-end relationship and top to bottomrelationship.

[0098] The panel 12 as shown in FIGS. 3(a) and (b) defines on one side,a moulding surface 15 which is reinforced by a rectangular configurationof webbing 16 on the rear side of the surface 15, the webbing 16defining peripheral flanges 17 of suitable width (W) for overlapping andcooperative engagement with an adjacent panels 13. The flanges 17 mayalso be reinforced by webbing 16′ in a similar manner on the sidedthereof opposite the moulding surface 15. The corners of the flanges 17are truncated at 45 degree as at 18 to truncate the corners of therectangular moulding surface 15 to enable interlocking with adjacentpanels 13 as shown in FIGS. 4 and 5. Holes 19 are provided in theflanges 17 of the panels 12 for interconnection with the panels 13 asdescribed further below, the reinforcing webbing 16′ forming bossesaround the holes 19. The number of holes 19 may vary depending on therequirements.

[0099] The panels 13 as shown in FIGS. 3(a) and (b) have a mouldingsurface 20 of rectangular configuration of a size substantially equal tothe surface 15 less the width of the flange 17 of the panel 12. Thesurface 20 is stepped forwardly of a surrounding peripheral flange 21having a width “W” by a distance substantially equal to the thickness ofthe flange 17. As with the panel 12, the flange 21 is truncated at 45degrees at the corners 22 and includes holes 23 in the flange 22positioned for alignment with the holes 19 in the flange 17 of the panel12. The mould surface 20 can be reinforced by webbing 24 on the rearside thereof and similarly the flanges 21 can be reinforced by webbing24′ which also forms bosses around the holes 23.

[0100] For the bottom top and ends of walls, flanges of the mould panels12 and 13 may be deleted as shown in FIGS. 4(a) and (b) to define plainedges 25 and 26 for the panels. The plain edges 25 and 26 are located atthe top and bottom and ends of the walls or at corners of the walls todefine a square corner.

[0101] Whilst the panels 12 and 13 are shown to be of differentconfigurations they may be constructed identically for example if theyare of a solid form or provided with an external skin surrounding forexample a foam core with panels 12 and 13 arranged in an oppositerelationship relative to each other with opposite faces thereof definingopposite mould surface. Because the alternate panels 12 and 13 shown inthe drawing, however are handed as shown in FIGS. 2 and 3, colour codingor the use of numerals, letters or symbols may be used to identify thedifferent panels to ensure that they are assembled correctly.

[0102] Panels 12 and 13 are arranged as shown in FIGS. 5 and 6, with, inside-by-side panels 12 and 13, the flange 17 of one panel 12 overlappingthe flange 21 of the other panel 13 and with the respective holes 19 and23 being aligned. Similarly in upper and lower panels 12 and 13, theflanges 17 of the panels 12 overlap the flange 21 of the other panels13. In diagonally arranged identically panels 12 or 13, the truncatedcorners 22 or 18 of adjacent panels 12 or 13 are juxtaposed. As isapparent in FIG. 6, the mould surfaces 15 and 20 of interconnectedpanels 12 and 13 are coplanar and panels 12 and 13 are arrangedalternatively one above the other in a non-staggered relationship andsimilarly alternatively in a side by side relationship. A flexibleadhesive tape 27 of any suitable specification may be placed around thecircumference of every alternate panel 12 or 13 including betweenjuxtaposed truncated corners 18 and 22. This caters for expansion of themould panels 12 and 13 which is expected to be more than the concrete.Alternatively the flexible adhesive tape may be any suitable flexiblematerial of any section that may mate with a suitable section around thecircumference of every alternate panel 12 or 13.

[0103] The panels 12 and 13 in the opposite moulds 11 are interconnectedby means of a plurality of transverse connector pins 28 whichadditionally extend between the moulds 11 and hold the moulds 11 at arequired spacing to form a mould cavity 29 into which concrete or othersettable material is poured. The transverse connector pins 28 as shownin FIGS. 7 to 9 are of elongated form and provided with integrallyformed spaced apart flanges 30 that serve to fix the spacing between themoulds 11 by abutting against the mould faces 14 of the moulds 11. Thepins 28 also have spigots 31 at each end extending outwardly of theflanges 30, the spigots 31 having enlarged bosses 32 of a lengthslightly greater than width of joined panels 12 and 13 so as to permitmould panels 12 and 13 to move relative to each other to a limitedextend as described further below. The outer ends of the spigots 31 areprovided with a pair of spaced slots 33 and 34 which extend through thespigots 31. The pins 28 however may only include one slot 33 at one endand a pair of slots 33 and 34 at their opposite ends or single slots 33at each end depending upon the method of supporting the panels 12 and 13during moulding as described further below and where the pins 28 are tobe used. The bosses 32 are joined to the flanges 30 via undercutportions 35 (see FIG. 10) which facilitate the breaking off of thespigots 31 as described further below. The ends of the spigots 31 areformed with opposite flats 36 for engagement with a complementary socket37 of a break off tool 38. Wedge shaped members 39 of a thicknessslightly less than the thickness of the slots 33 and 34 are provided forinsertion into the slots 33 and 34. The flanges 30 may be provided withopposite flats 40 to prevent rotation of the pins 28 during thebreak-off procedure as described below. The pins 28 are typicallymoulded from plastic but may be of any suitable material.

[0104] The holes 19 and 23 are of a greater diameter than the diameterof the bosses 32 and some or all of the holes 23 in the panel 13 (andholes 19 in the panels 12) may be counter bored at 41 to receiveflexible bushes or ‘O’ rings 42. The flexible bushes or ‘O’ rings 42 arelocated at suitable locations and are provided to centrally locate thetransverse connector pins 28 within the aligned holes 19 and 23 in thepanels 12 and 13 to permit the mould panels 12 and 13 to move relativeto each other to a limited extend to control overall expansion.

[0105] An alternative configuration of pin 28 is shown in FIG. 12 inwhich like components to the components of the pin 28 have been givenlike numerals, the spigot 31 may be formed with first and secondthreaded sections 43 and 44, the threaded section 43 being arrangedadjacent to the boss 32 and the threaded section 44 being at the freeend of the spigot 31. The threaded section 43 has a larger diameter thanthe threaded section 44. The threaded section 43 terminates at ashoulder 45 at the junction with the boss 32 and the threaded section 44terminates at a shoulder 46. The threaded sections 43 and 44 arearranged for threaded cooperation with a pair of nuts, only one of which47 is shown in FIG. 13. The nut 47 for engagement with threaded section43 may be passed over the spigot 31 and threaded section 44. The nuts 47when urged into engagement with the shoulders 45 or 46 and with torqueapplied will cause the spigot ends to break off at the undercuts 35. Fortightening and break-off purposes, the nut 47 has opposite flats forengagement with a suitable tool such as a spanner. In an alternativearrangement, the nuts 47 may be conventional hexagonal nuts. Thedistance between the flange 30 and shoulders 45 and 46 is such as toallow limited longitudinal movement of the panels 12 and 13 when securedto the spigots 31 by the nuts 47.

[0106] To support the moulds 11 and mould panels 12 and 13 during thewall construction process, support frames 48 and 49 of alternativeconfigurations may be employed as shown in FIGS. 1, 14 and 15. Thesupport frames 48 are braced frames and include a horizontal member 50and a braced vertical member 51. The support frames 49 are unbracedframes and also include a horizontal member 52 and an upright member 53.The upright members 51 and/or 53 of adjacent frames 48 or 49 are tiedtogether by elongated spanning members 54 which may be of angle sectionform. The horizontal members 50 and 52 of the frames 48 and 49 may beprovided with levelling screws 55 (see also FIG. 17). The levellingscrews 55 are threaded into threaded bushes 56 secured within thehorizontal members 50 and 52 which are preferably of tubular form anddrilled to accept the bushes 56. Screws 57 secure the bush 56 to themembers 50 or 52. The levelling screws 55 have a reduction spigot 58 sodesigned as to be able to be peened over to accept a platform washer 59which is allowed to rotate. The levelling screws 57 enable the frames 48and 49 and attached wall panels 12 and 13 primarily to be jacked up aswell as allowing vertical adjustment of the wall panels 12 and 13 afterthey have been jacked up. In a simplified form, the frames 48 and 49 maybe provided with no levelling screws and the frame 49 may also beprovided without the leg 52 thereby forming a simple post. The frames 48and 49 are typically constructed of steel. The frame 48 may be designedto fold at strategic locations for ease of transport.

[0107] An alternative support frame 60 is shown in FIGS. 1 and 16, theframe 60 including a normally upright member 61 pivotally connected at62 to a horizontal member 63. The horizontal member 63 may be providedat its outer end with an outrigger foot 64. The members 61 and 63 may beheld at an adjustable angle via an adjustable split diagonal rod 65pinned to the members 61 and 63 by pins 66 and 67. A turnbuckle 68 isprovided intermediate the ends of the split rod 65 which when rotated inopposite directions will extend or retract the length of the rod 65 andthus vary the attitude of the upright member 61 relative to thehorizontal member 63. The support frame 60 will be preferred in mostsituations as it allows for vertical adjustment of the moulds under allsituations to ensure that the wall is constructed vertically. Thesupport frame 60 may also have levelling screws as used on the frames 48and 49 as referred to above.

[0108] The upright members 51, 53 and 61 are provided with apertures 69spaced apart the distance between the apertures 19 and 23 in the panels12 and 13 in the vertical direction to allow connection by the pins 28as described further below.

[0109] Referring to FIGS. 1, 18 and 19, a wall constructed using theapparatus 10 according to the present invention may be moulded directlyonto a floor slab 70 having protruding starter bolts or bars 71. Ifdifferential expansion exists or is expected between the slab 70 and thewall, the wall may be moulded about flexible junctions or sleeves 72located about the starter bolts or bars 71.

[0110] The starter bars 71 come directly out of the floor slab 70 andmay have right angle bends 73 (which may be formed on site) to lock intothe concrete of the wall as shown or have a screwed connector 74 intowhich vertical reinforcing rods 75 are screwed. In the case of a starterbar with a bend 73, a vertical reinforcing rod 75 may be tied to it bysuitable ties 76. The flexible sleeves 72 may be longitudinally split toallow fitment if a starter bar 71 with a right angle bend is used.

[0111] In an alternative arrangement, starter bars 71 may be fixed insliding mounts 77 (see FIGS. 18, 20 and 21 which are cast within theslab 70 to accommodate relative movement between the wall and slab 70.The mount 77 is designed to be cast into the floor slab 70 and allowexpansion movement of the wall moulded over it. It can also provide someenergy absorption during earthquake. The mount 77 includes a ferrule 78fixed onto a disk 79 or alternatively those components may be integrallyformed. Disk 79 is assembled between two other disks 80 and 81 which arelocated at a certain distance apart by annular ring 82 which creates adesign clearance 83 at the top and bottom of the disk 79. Disks 80 and81 include grooves 84 in which flexible rings 85 are carried which maybe of any section or round and which may be ‘O’ rings or any specialdesign. The flexible rings 85 bear on the plate 79 on opposite sides tosupport the plate 79 in its sliding movement. The rings 85 also serve asenergy absorbers where the mount 77 is used for example in earthquakeenvironments.

[0112] The design clearances will enable the disc 79 to slide freelyradially and to prevent any jamming if the mount 77 is installedslightly off vertical, thereby allowing some installation tolerance. Acap 86 typically formed of plastics is designed to securely clip andlocate into a central hole 87 in the top disk 80, the hole 87 having achamfer 88 around its periphery. The cap 86 has a hole 89 at its upperend that locates tightly about the ferrule 78. The cap 86 prevents wetconcrete ingress into the mount and centres the sliding mount 77 duringmoulding. A flexible annulus 91 of any suitable material is locatedbetween the disk 79 and the annular ring 82 to allow adequate movementof disk 79 but cushion and centralise it. Alternatively, a flexibleannulus 92 may be located within the cap 86 between the ferrule 78 andhole 87 in the plate 80 and perform the same function. Each annulus 91or 92 also will serve to absorb energy which may be encountered inearthquakes.

[0113] The chamfer 88 in the top disk 80 is designed to clear any weldbetween the ferrule 78 and disk 79. If the flexible annulus 91 isemployed the top disk 80 may be attached with screws 93 instead ofwelding 94 to prevent burning of the flexible annulus 91 during welding.The annular ring 82 may be welded to the bottom disk 81. A securing bar94 is welded to the bottom disk 81 and includes a right angled bend toembed firmly into the concrete of the slab 70. Ferrule 78 may bethreaded as at 95 to accept a threaded reinforcing rod or may be plainbored to accept a rod which is in turn welded to it. The slidingcoupling is self centering during moulding and is designed allow alimited radial deflection in all directions before solid contact occursbetween the sliding disk or ferrule with other fixed parts of the mount77. In use, the concrete of the wall is cast onto the floor slab 70 overthe upwardly protruding cap 86 and when or if the wall moves relative tothe floor slab 70, the cap 86 will break to allow this movement, the cap86 being designed to deliberately fall in these circumstances.

[0114] For construction of a wall, flexible adhesive tape or anysuitable flexible material of any suitable section is wrapped around theperiphery of each alternative panel 12 or 13 and these mould panels 12and 13 are assembled in the manner shown and described with reference toFIGS. 5 and 6 with the flexible material sandwiched between oppositeedge portions of the panels 12 and 13. Where mould panels 12 and 13having plain edges 25 are used, the tape is not used on the plain edges25. The assembled mould panels 12 and 13 are arranged at spaced apartpositions on opposite sides of the starter bars 71 or mounts 77 andinterconnected by means of the connector pins 28 as shown in FIG. 7 toform both moulds 11. In one option for assembly, one set of panels 12and 13 for one mould 11 may be assembled by inserting the spigot ends 31of the pins 28 into the aligned apertures 19 and 23 where they may beheld by the bushes 42. The other set of panels 12 and 13 for the othermould 11 may then be aligned with the aligned openings 19 and 23 thereininserted over the free ends of the pins 28 with the reinforcing arrangedbetween the moulds 11 as the construction proceeds. Where the panels 12and 13 are supported by frames 48, 49 and 60 on one side only, theinterconnecting pins 28 need only have a single slot 33 for cooperationwith a wedging member 39 to hold the panels to the pins 28 at theposition remote from the frames 48, 49 or 60.

[0115] When the pins 28 are passed through the aligned holes 19 and 23in the mould panels 12 and 13, the outer annular faces of the bosses 30will abut against the mould faces 14 of the moulds 11 to act as spacersto hold the moulds 11 at a fixed spacing relative to each other andinterconnect the panels 12 and 13 to hold the panels in an end to endrelationship with each other with the mould surfaces 15 and 20 thereofcoplanar. Panels 12 and 13 are also assembled one above the other andthe panels 12 and 13 may be held connected to each other by further pins28 passed through the aligned holes 19 and 23 in the centre of thepanels 12 and 13. The assembled panels 12 and 13 are supported on one orboth sides by the support frames 48, 49 or 60 with the spigots 31 of thepins 28 passing through the apertures 69 in the upright members 51, 53or 61 of the support frames 48, 49 or 61. The panels 11 and 12 are heldto the upright members 51, 53 or 60 by means of the wedge shaped members39 which are passed into the outer slots 34 of the spigots 31. As statedhowever, the boss 32 ensures that the mould panels 12 and 13 are alwaysfree to move relative to each other in a direction normal to the pins 28and are thus not locked up even when secured by the wedge shaped members39 to the upright members 51, 53 and 60. The outer slots 34 are usedwhere the frames 48, 49 and 60 are used whilst the inner slots 33 areused for receipt of the wedge shaped members 39 when it is desired tohold the panels 12 and 13 to the pins 28 in the absence of the frames48, 49 and 60.

[0116] Alternatively, where pins 28 with ends of the type shown in FIG.12 are employed, the panels 12 and 13 are held to the upright framemembers 51,53 and/or 60 by nuts 47 engaged with the threaded portion 44which is screwed up into abutment with the shoulder 46. In the absenceof the frame members 51,53 and/or 60, a nut 47 is engaged with thethreaded section 43 and screwed up to the shoulder 45. The spacing ofthe shoulders 45 along the spigot 31 is such that when either a nut 47or frame member 53, 51 or 63 abuts the shoulder 45, panels 12 and 13 arefree for longitudinal movement relative to each other in a directionsubstantially normal to the pins 28.

[0117] The leveling screws 55 when employed, are used to jack up thepanels 12 and 13 if required and then adjust the upright attitude of theframe members 51 and 53 and thus the panels 12 and 13 to ensure avertical wall. Alternatively, the turnbuckle 68 may be adjusted toadjust the vertical attitude of the panels 12 and 13 where the frames 60are used.

[0118] The elongated members 54 which interconnect adjacent frames 48,49 and/or 60 through the pins 38 are used to maintain the overall lengthof the assembled wall mould panels 12 and 13 by fixing the position ofpins 28. The member 54 has holes to locate over the spigots 31 of theconnector pins 28 and is also secured to the pins 28 by means of thewedges 39 (or nuts 47). In for example FIG. 7, the members 54 may belocated between the frame members 51, 53 or 61 and wedge 39 whichbecause of its configuration will adjust to the additional width of themember 54. The elongated member 54 may be of any suitable length andusually one row of members 54 on the top and bottom of the moulds 11 isrequired.

[0119] Where the wall is to be constructed on a floor slab 70, animpervious membrane or layer 96 which may be a sheet like material maybe initially placed on the slab 70 which prevents the concrete bondingto the slab 70 thereby forming a slip joint and allows independentexpansion of the concrete wall relative to the slab 70 (see FIG. 19).The impervious membrane 96 may be relatively thin however in locationswhere earthquakes may be encountered, the membrane 96 may be ofincreased thickness to absorb energy. Vertical reinforcing rods 75 aresecured to the starter bars 71 or mounts 77, and horizontal steel bars97 may be tied to the vertical bars 75 as shown in FIG. 18 at the pointsof crossover 98. The horizontal bars 97 may also be tied to thetransverse connector pins 28 as shown at 99. For this purpose, the pins28 may have a central aperture 100 (see FIG. 7) which facilitates tyingof the bars 97 to the pins 28 at a central location within the mouldcavity 29.

[0120] After assembly of the mould as above, concrete is then poured ordeposited between the moulds 11 into the cavity 29 and onto theimpervious membrane 96 to encapsulate the pins 28 and reinforcing 75 and97 and the concrete is then allowed to cure. If the wall moves due toexpansion during curing or after curing for example if the wall heats upto due to exposure to sunlight whilst the floor slab remains cool, itmoves on the impervious membrane 96 and movement will also beaccommodated by the flexible mounts 72 which allows bending of thestarter bars 71 within the formed wall. Where the mounts 77 for thereinforcing bars 75 are used, the cap 86 is designed to break to allowmovement of the wall relative to the slab 70.

[0121] After the concrete has cured, the wedge-shaped members 39 areremoved, the break-off sockets 37 of the tools 38 are located over theends of the projecting spigots 31 and twisted to break the spigots 31off at the undercuts 35. This leaves the pins 28 behind in the mouldedconcrete wall. Where pins 28 having the threaded ends are used, a torquemay be applied to the nuts 47 such that they are urged up harder againstthe shoulders 45 or 46 until the spigots 31 break off again at theundercuts 35. In each case, the flats 40 which are surrounded byconcrete prevent the pins 28 from turning during the break offoperation. Any remains of the pins 28 after breaking off may be dressedoff flat with the rest of the wall. The panels 12 and 13 may be removedeither before or after breaking off the spigots 31 of the pins 28.

[0122] In construction walls as above, in some instances the slab floor70 may not be level. In this case, it is necessary to jack up the mouldpanels 12 or 13 via the frames 48 or 49 using the leveling screws 55 asshown in FIG. 22. This creates a gap 101 at the bottom of the mouldpanels 12 and 13 and a filler panel 102 is used to close the gap 101.The panel 102 as shown in FIG. 22 is shaped to slide between the mouldpanels 12 and 13 and pins 28 and may be made of any suitable material.The panel 102 includes spaced slots 103 which fit over the pins 28. Thepanel 102 prevents concrete leakage during moulding.

[0123]FIGS. 24 and 25 illustrate a holding down arrangement for themoulds 11 defined by the mould panels 12 and 13 for constructing aninternal wall without starter bars. Where an internal wall is notrequired to be tied down to the slab (i.e. no starter bolts or mounts)and/or does not contain steel reinforcing it may be necessary to tie themoulds 11 down to prevent them floating up during moulding. For thispurpose, a securing plate 104 is mounted to the slab 70 in the correctlocation using an anchor bolt 105 and panels 12 and 13 assembled onopposite sides of the plate 104. The lower edges of the lowermost panels12 or 13 may be required to have slots to accommodate the plate 104.This plate 104 is joggled enabling hooked rods 106 to be slid under theopposite sides thereof. The rods 106 are attached to a stirrup 107 viavertical adjusters 108 which may be turnbuckles. The stirrup 107 passesover the upper ends of the moulds 11 and flexible pads 109 may beemployed above the mould panels 11 beneath the stirrups 107 to preventthe mould panels 12 and 13 being damaged. After pouring and curing ofthe concrete between the moulds 11, the moulds 11 may be disassembledand protruding ends of the plate 104 may be severed. If an internal walldoes not incorporate steel reinforcing, the concrete for forming thiswall may be reinforced with a material such as fibre.

[0124] An alternative arrangement is shown in FIG. 26 with a doublejoggled securing plate 110 that allows nuts 111 to be installed aboveand below it engaged with an elongated anchor screw 112 thereby allowingjacking up of the moulds 11 via the longer screw 112 set within theslab. This compensates for out of level of the slab or footing.

[0125] For incorporation of door openings during construction of wallsusing the moulding apparatus and method of the invention, frames 112 and113 of an exact width to fit between the mould panels 12 and 13 may bebuilt into the mould 11 (shown in dotted outline) as the moulds 11 areconstructed as shown in FIG. 27. The frames 112 and 113 create the dooraperture and are left in place after the concrete forming the wall isset to enable mounting of doors. Some mould panels 12 and 13 may be leftout as shown at 114 during the construction of the mould because theyare within the aperture of the door frame 113.

[0126]FIGS. 28 and 29 illustrate the use of a subfloor link assembly 115under doors or openings which may be necessary to stop cracking of theconcrete around doors due to movement of the adjacent walls relative tothe floor slab 70 as allowed by the flexible connections to the starterbars of the floor slab as described above or by the sliding mounts 77.For installation of the subfloor link assembly 115, a trench 116 ismoulded in the slab 70 across the location of the door frame 117 oropening using a suitable foam plastic insert in the slab 70 duringmoulding which later may be dissolved with suitable solvent resulting informing the trench 116. A steel reinforcing rod 118 is inserted in thetrench 116 prior to moulding of the walls. The rod 118 is bent at rightangles at each end at 119 to protrude vertically into the wall mouldcavity 29 at appropriate locations at either side of the door apertureor opening defined by the frame 117. Sheet metal cover plates 120 and121 are positioned over the trench 116, the ends plates 121 having holes122 to receive the vertically protruding ends 118′ of the rod 118 toprevent concrete leaking into the trench 116 during moulding of thewall. The holes 122 in the plates 121 are sealed with suitable sealant123. The protruding ends 118′ of the rod 118 may be tied at each end tothe adjacent steel reinforcing within the wall mould cavity 29 forexample to the rods 75 at each side of the door frame 117. Theimpervious membrane 96 where used overlaps with the end cover plates121.

[0127] After moulding of the wall, the cover plates 120 are screwed tothe slab floor 70 via fixings at 124 to cover the exposed trench in thedoor aperture or opening, or alternatively it may be cemented to theslab using suitable adhesive to render it flush. An appropriate smallgap 125 is left between adjacent cover plates 120 and 121 to allow somemovement of the walls next the door frame 117 relative to the slab 70due to expansion.

[0128] Where concrete wall moulds 11 exceed certain length limits,expansion joints 126 as shown in FIGS. 30 and 31 may be incorporatedbetween adjacent wall mould sections. The expansion joint 126 includescomplementary sections 127 and 128 typically formed of sheet metal, bothsections 127 and 128 being of generally channel shaped form with thesection 127 having a protuberance 129 that is a slide fit inside acomplementary recess 130 in section 128. The sections 127 and 128 haveside flanges 131 and 132 having slots 133 and 134 which are spaced aparta distance to align with connecting pins 28 between the mould 11. Thesections 127 and 128 are assembled by sliding the flanges 131 and 132between the mould panels 12 and 13 and the flanges 30 on the pins 28before the wedges 39 (or nuts 47) are installed. The sections 127 and128 may be left in place or removed after the concrete forming the wallhas set. A flexible elastic medium 135 of suitable material is thenplaced between the sections 127 and 128 on opposite sides of theprotrusion 129 and recess 130. The medium 135 may be of the liquidsealant type which cures over time. The steel reinforcing 136 within themoulds 11 extends close to the sections 127 and 128.

[0129]FIG. 32 shows an alternative expansion joint 137 which usessections 138 and 139 similar to the expansion joint sections 127 and 128however in this case the transverse dimensions of the sections 127 and128 are such that the side flanges thereof locate about the pins 28 onthe outside of the mould panels 12,13. This enables the sections 138 and139 to be easily removed after the concrete forming the wall has setthereby forming a joint that comprises reinforced concrete alone and notincluding the sections 138 and 139. The sections 138 and 139 maytherefore also be reused.

[0130] To stop the expansion joints 126 and/or 137 opening too far whenflexible connections are provided between the wall reinforcing and theslab starter bars or where the reinforcing mounts 77 are used, expansionjoint limiters 140 may be employed to interconnect adjacent wallsections on opposite sides of expansion joints 126 or 137 as shown inFIG. 33. The expansion joint limiters 140 are in the form of plates 141which are secured between walls by suitable anchors 142 but which allowlimited movement of the wall sections. Each plate has an enlargedaperture or slot 143 at one end to receive an anchor 142 to allowmovement of the anchor 142 relatively along the slot 143 during relativemovement between the adjacent wall sections. The limiters 140 may belocated as desired and if necessary can be concealed above the soffit ofa building.

[0131] For formation of a buttress wall, end sections 144 of generallychannel shaped form as shown in FIG. 34 are secured to the ends ofmoulds 11, the end sections 144 being mounted in a similar manner to thesections 138 and 139 of FIG. 31 and being removable after moulding ofthe wall.

[0132] Where corners of a wall are to be constructed, inner and outercorner mould panels 145 and 146 are provided as shown in FIGS. 35 and36, each being of right-angle section form and typically being plasticextrusions and having opposite square edges. The main mould panels 12and 13 for use with the corner mould panels 145 and 146 also have endsquare edges adjacent the moulds 145 and 146 as described with referenceto FIGS. 2 and 3. The corner mould panels 145 and 146 are provided alongopposite edges with holes 147 and 148 spaced for alignment with theholes 19 or 23 in the panels 12 and 13 for close receipt of the spigots31 of the pins 28. Some of the holes 147 and 148 may be enlarged orslotted to allow for expansion of the plastic (or other material) of thecorner mould panels 145 and 146.

[0133] Bridging plates 149 (see FIG. 39) are used to connect the cornermould panels 145 and 146 to the main mould panels 12 and 13. Thebridging plates 149 have holes 150 at the same pitch as the holes in themould panels 11 and 12, 145 and 146. The pins 28 are used tointerconnect the panels 12 and 13 with the corner mould panels 145 and146 via the plates 149 located on the outside of the panels with supportframes 48,49 or 60 used where required as shown. Corner steelreinforcing is provided at 151 within the corner to establish therequired strength. After pouring of the concrete between the moulds 11defined by the mould panels 12 and 13 and mould panels 145 and 146, thepin spigots 31 are broken off with the wrench 38 as described previouslyafter the concrete is set.

[0134] Referring now to FIG. 37, there is illustrated the mouldingarrangement for a T-junction 152 which may be incorporated into a wall.Mould panels 12 and 13 with plain square edges are again required inorder to present a flat edge to the T-junction moulds which comprise asalso shown in FIG. 38 a rear planar mould panel 153 and a pair ofright-angle mould panels 154, each of which also have plain square edgesand are typically plastic extrusions but may be made by any method andbe of any material and which include along their opposite side edgesspaced holes 155 and 156 for alignment with the holes 19 and 23 in thepanels 12 and 13 and also the bridging panels 149. The mould panels 12and 13 are joined in edge-to-edge relationship by bridging members 149(see FIG. 39) to the respective mould panels 153 and 154 through thealigned holes and by means of the pins 28 as illustrated. The bridgingmembers 149 may be in various configurations depending upon theconfigurations of the mould panels 145 and 146 of FIG. 35 and of themould panels 153 and 154. For example the mould panels 145, 146, 153 and154 may be of thin wall construction and reinforced by webs thusrequiring the bridging members 149 to be used with spacer spigots orhave inwardly directed flanges to align the moulding faces of the mouldpanels 145, 146, 153 and 154 with those of the panels 12 and 13 to whichthey are joined.

[0135] Corner steel reinforcing 157 and straight reinforcing 158 isrequired within the tee junction 152 to establish the required strength.The rear mould panels 153 and angle mould panels 154 may be sized sothat the rear mould panel 153 spans the same length as the standardlength panels 12 and 13 to simplify construction of the opposite wall.

[0136] FIGS. 40 to 42 illustrate the manner in which a wall may bemoulded around windows. Upright support frames or posts 159 and 160 arelocated at spaced apart positions to define opposite sides of a windowopening 161 and aligned with opposite moulds 11 defined by joined mouldpanels 12 and 13. Horizontal support frame assemblies 162 and 163 arelocated in the areas above and below the window to support the moulds.Window surround moulding panels 164 and 165 fit over the mould panels 12and 13, support frames 162 and 163 and posts 159 and 160, being securedin position by the pins 28 as shown. For this purpose, side flanges ofthe panels 164 and 165 have slots 166 which align with and locate overthe pins 28 joining respective panels 12 and 13. The frames 162 and 163located above and below the window opening are fixed to the posts 159and 160 via plates 167. The side moulding panels 165 have flanges 168which are attached by screws 169 to the top and bottom window surroundmoulding panels 164. During moulding, horizontal braces (not shown) maybe temporarily placed between the panels 165 to provide support andprevent collapse or bowing of the panels 165. Vertical braces may alsobe provided between for example the panels 164 to provide support whererequired. The braces may be held in position by screws or any otherreleasable fasteners. Similar braces may be used in association with thedoor frames 112 or 113 or in any other defined opening in a wall beingmoulded where required.

[0137] An alternative preferred window surround moulding panel 170 isshown in FIGS. 43 and 44 which includes in this case a rebate 171 tolocate the windows, a mitre 172 to enable mating with a mitre on thecorresponding top and bottom window surround moulding panels and twoindividual apertured lugs 173 for securing the panels 170 to thecorresponding top and bottom panels 164 (in place of the flange 168).

[0138] When the alternative mitred panels 170 are used, it is necessaryto split the side panels into three parts 174, 175, and 176 as shown inFIG. 45 to enable removal of the panels. The central section 170 isrequired to include slots 160 to enable clamping by the pins 28. Thewindow surround moulding panels may be metal or any suitable material.

[0139] In use the window surround moulding panels 164 and 165 (and/or170) are left off until the concrete is poured to the level of the sillor lower window surround moulding panel. The window surround mouldingpanels are then assembled before the remainder of the concrete ispoured.

[0140] FIGS. 46 to 48 show the configuration of panels at corners of thewindow opening for example in the region F of FIG. 40 looking directlyat the mould face. The corner window mould panels 178 and 179 aresimilar to panels 12 and 13 with plain edges as described with referenceto FIG. 4 except that they have 45 degree mitres 180 on the flanges 181and raised protuberances 182 with an edge perpendicular to the 45 degreemitres 180, the protuberances 182 being flush with the moulding surfaces183 and 184. This allows the panels 178 and 179 to mate with an adjacentconventional panel 12 that is placed as indicated by the arrow 185 andlocates on and overlaps the flanges 181. The corner window mould panels178 and 179 may be distinguished and identified by colour andidentification coding.

[0141]FIG. 49 illustrate a plastic conduit 185 that is placed at andspans the junction of the slab 70 and the wall cavity 186 at thelocation where cables and pipes pass. The conduit 185 also passesthrough the impervious membrane 96 (where used). The conduit 185 issized larger than the cables or pipes to be passed therethrough.Flexible conduits 187 are attached to opposite ends of the plasticconduit 185 before moulding of the wall to enable carrying of the pipesor cables. The plastic conduit 185 will allow expansion movement of thewall 186 relative to the slab 70 by a shearing failure at the slab/walljunction however because this conduit 185 is oversize, the cable orpiping within is not damaged.

[0142] Referring now to FIGS. 50 to 52, there is illustrated analternative connecting pin assembly 188 for interconnecting panels 12and 13 and moulds 11 defined thereby which may be used instead of thepins 28. The pin assembly 188 includes an outer elongated sleeve 189which may typically be formed of a plastics material and may terminateat each end in flanges 190 which are equivalent to the flanges 30 of thepin 28 but the flanges 190 are not required to have the flats equivalentto flats 40 on the flanges 30 of pin 28. The sleeve 189 also includesinternal dimples 191 intermediate the ends thereof for a purpose whichwill become apparent below. The pin assembly 188 also includes anelongated pin 192 which has a central portion 193 of a diametersubstantially the same as the diameter of the sleeve bore 194 and alength greater than the sleeve 189 to define bosses 195 equivalent tothe bosses 32 of the pins 28. The pins 192 are typically metal but maybe of any suitable material. The pins 192 also include oppositespigot-like ends 196 of reduced diameter. If desired, the pin 192 maycomprise an inner pin member which defines and is of the diameter of thespigot-like ends 196 and an outer tubular sleeve member which is of theouter diameter of the central portion 193 and bosses 195 located aboutthe inner pin member, the outer tubular sleeve member defining thecentral portion 193 and bosses 195 of the pin assembly 188. Thisconfiguration of pin 192 may assist assembly of the panels 12 and 13 toform the wall mould. The spigot-like ends 196 have spaced slots 197 and198 equivalent to the slots 33 and 34 of the pin ends 31. As referred toabove however the pins 192 may have only one slot 197 at one end and thepair of slots 197 and 198 at the opposite end or single slots 197 onlyat opposite ends. Alternatively the spigot-like ends 196 may be threadedas in the embodiment of FIGS. 12 and 13.

[0143] For assembling moulds panels 12 and 13 to form moulds 11, thepins 192 are inserted into the bores 194 of the sleeves 189 and are heldfrictionally by the dimples 191 so that ends of the pins 192 projectequally from opposite ends of the sleeve 189. The pin assemblies 188 arethen used in the same manner as the pins 28 with the flanges 190abutting the inner faces 14 of the moulds 11 to set the spacing betweenthe moulds 11 and the spigot-like ends 196 and bosses 195 projectingthrough aligned holes 19 and 23 in the panels 12 and 13. The spigot-likeends 196 are also passed through the support frames 48, 49 or 60 whereused. The spigot-like ends 196 and bosses 195 also pass through theflexible bushes 42 which also seal the ends of the sleeve 189. The pinassemblies 188 are then secured to the panels 12 and 13 (and the supportframes where used) by the wedges 39 where the slots 197 and 198 are usedor by nuts where the spigot-like ends 196 are threaded. The concretemoulding process is then undertaken as before and after the concrete hascured, the pins 192 are withdrawn lengthwise from the sleeves 189, thelatter remaining embedded within the concrete of the moulded wall. Theends of the sleeve 189 which have been sealed by the bushes 42 may thenbe closed by bungs 199 which may be formed of plastics or any othermaterial. As shown the bungs 199 preferably have a flanged head 200 andthe sleeve bore is countersunk at each end as at 201 to receive theheads 200 of the bungs 199 such that the heads 200 of the bungs 199 canlocate within the countersunk portions 201 to be flush with the sleeveflanges 190.

[0144] The sleeve 189 may additionally be provided with a pair of spacedflanges 202 arranged centrally of the sleeve 189 to locate reinforcingrods (shown in dotted outline) which may be tied to the sleeve 189. Theabove described configuration arrangement of pin assembly allows thepins 192 to be reused. The flanges 202 however are not essential andother means may be provided for locating the reinforcing.

[0145] Referring now to FIGS. 53 and 54, there is illustrated analternative method of moulding around windows using the mouldingapparatus and method of the invention similar to the manner ofinstalling door frames as described with reference to FIG. 27. In thismethod, a rectangular perimeter frame 203 defined by moulding panels ofexact width to fit in the cavity 29 between the moulds 11 defined bymould panels 12 and 13 (shown in dotted outline) may be installedbetween the moulds 11 as the moulds 11 are constructed thereforecreating the window aperture 204. Some mould panels 12 and 13 may beomitted in the window aperture area 204 to allow access. On the bottomsill-defining horizontal member 205 of the frame 203, access holes 206are provided which allow filling of the mould cavity 29 up to the levelof the frame member 205. Cover plates 207 are provided to close theholes 206 during moulding, the cover plates 207 carrying blanking plates208 which are of complementary shape to the holes 206 being secured tothe cover plates 207 by screws 209 or other releasable fasteners. Thecover plates 207 with attached blanking plates 208 are secured to thebottom frame member 205 by further screws 210. On completion of themoulding, the cover plates 207 are removed by removing the screws 210and at the same time, the screws 209 are removed leaving the blankingplates 208 behind to fill the access holes 206. The sill-defining member205 may also be provided with a series of spaced air expulsion holes 211to allow escape of air as concrete is filled the mould cavity 29 beneaththe sill-defining member 205. The holes 211 may be plugged with screwsafter concrete has filled the cavity up to the member 205. Similar airexpulsion holes may be provided in the lower moulding panel 164 (seeFIG. 40). The frame 203 may be made collapsible to enable it to beremoved if removal is required. Normally however, the frame 203 remainsin situ within the moulded wall.

[0146] Many other shapes may also be moulded into the walls by the useof appropriate moulding members of inserts interposed between theopposite moulds 11. For example, a curved moulding member 212 (shown indotted outline in FIG. 27) may be use in combination with a doormoulding frame 113 to form an arch. Similarly, to form gables as shownin FIG. 55, angled moulding members 213 may be provided between themoulds 11 (shown in dotted outline) with the mould members 12 and 13along the line of the gable being of stepped inwardly to the peak of thegables. The moulding members 213 may comprise single moulding members oralternatively a series of aligned moulding members. Of course themoulding members 213 may be of any profile such as a curved profile toform a curved shape at the upper side of a wall.

[0147] Referring now to FIGS. 56 and 57, there is illustrated analternative method and apparatus for erecting moulds for moulding wallsof concrete or other settable material and using mould panels 12 and 13as described above for forming opposite moulds 11 and in whichlike-components to those used in the above described method andapparatus have been given like numerals. In this case, spaced apartsupport frames 60 (only two of which are shown) are initially erected ona slab or other foundation and in longitudinal alignment with eachother. Upper and lower horizontal members 203 and 204 are then securedbetween the support frames 60 and a series of vertical frame members 205erected between the upper and lower frame members 203 and 204 such as tocreate a grid.

[0148] Opposite ends of the horizontal members 203 and 204 are providedwith brackets 206 which are apertured for alignment with apertures inthe vertical frame members 61 to receive ends of the interconnectingpins, in this case the spigot-like ends 196 of the pins 192 of the pinsassemblies 188, the sleeves 189 having been removed. This connects themembers 203 and 204 to the vertical members 205. The vertical framemembers 205 are provided with similar brackets 207 for connection atupper and lower ends to the frame members 203 and 204 by means of thepins 192. The vertical frame members 61 of the support frames 60 and theframe members 205 are provided with apertures which are spaced apart thesame distance as the apertures in the panels 12 and 13 and further pins192 are positioned in these apertures to extend outwardly from themembers 61 and 205.

[0149] Panels 12 and 13 of the first mould 11 are then positionedalternatively in the correct sequence over the pins and pushed upagainst the frame members 61 203, 204 and 205. The flexible material 27may be provided about the periphery of alternate panels prior toassembly where required. As stated above, the flexible material 27 maybe of many different configurations and material and are suitably formedto enable the panels 12 and 13 to be moved laterally into position asillustrated and effect a seal between the panels 12 and 13. Pins 192 arealso positioned in the central slots in the overlapping panels 12 and13. The wedge members 39 may be located in the slots 198 of the pins ator prior to this time and thereafter the sleeves 189 are slid over thepins 192 and hard up against the panels 12 and 13. Reinforcing may thenbe placed in position being supported on the sleeves 189 and panels 12and 13 of the opposite mould 11 may then be positioned so that theapertures 19 and 23 are aligned with and can receive the projecting pinends 196. The wedge members 39 may then be placed in the slots 197 or198 to hold the panels 12 and 13 in position and define the cavity 29between the moulds 11 ready to accept concrete or other settablematerial. If desired upper and lower horizontal straps 208 may be placedover the pin ends 196 on the outside of the panels 12 and 13 to provideadditional support during the concrete pour to prevent wall bowing.After the pour, the wedge members 39 are removed from the pin ends 196,the supporting grid disassembled and panels 12 and 13 removed along withthe pins 192 leaving the sleeves 189 within the formed wall. Ends of thesleeves 189 may then be plugged by the bungs 199. Of course in the abovearrangement, pins 28 of the configuration previously described may beused in lieu of the pin assemblies 188.

[0150] The use of a grid formed by the members 61, 203,204 and 205 fixesthe position of the connecting pins 192 (or 28) and thus the position ofthe reinforcing supported by the pins whilst the panels 12 and 13supported on the pins are capable of a limited degree of longitudinalmovement.

[0151] Conduits may be laid within the moulds before the concrete ispoured to receive electrical cables and plumbing. Foam plastic blocksmay be mounted on the mould faces to create mounting cavities forswitches, power points etc. The blocks may be chemically dissolved afterthe wall is moulded. Frames and posts may be located using straightedges during construction of moulds. Mould panels may be deleted asrequired at desired locations eg. at openings.

[0152] Whilst the reinforcing used between the moulds is shown to be aplurality of interconnected reinforcing rods, the reinforcing maycomprise a reinforcing mesh. Further whilst the wall is described asbeing constructed upon a floor, it may be constructed upon any othersuitable foundation such as footings.

1. A method of constructing a wall of concrete or other settablematerial, said method including the steps of providing first and secondmoulds, each said mould comprising a plurality of mould panels, eachsaid mould panel having a moulding surface, arranging said mould panelsrelative to each other such that peripheral portions of adjacent saidmould panels overlap and said moulding surfaces are substantiallycoplanar to define mould faces of said first and second moulds,providing interconnecting means for holding said moulds at a desiredspacing to define a mould cavity therebetween, said interconnectingmeans extending through said overlapping portions of said mould panelsto interconnect at least adjacent side by side mould panels in each saidmould, depositing concrete or other settable material into said mouldcavity to form said wall, and removing said moulds after curing of saidconcrete or settable material.
 2. The method of claim 1 wherein saidinterconnection means interconnects said moulds and mould panels in sucha manner as to prevent movement of said mould faces transversely awayfrom each other but permitting limited movement of said panelslongitudinally relative to each other.
 3. A method according to claim 2and including the step of providing flexible or elastic means betweenmating edges of the mould panels to accommodate said limitedlongitudinal movement thereof.
 4. A method according to claim 2 or claim3 wherein said wall is constructed upon an existing floor and whereinsaid method includes the step of providing an impervious membrane orlayer between said floor and moulds to permit a constructed wall to moverelative to said floor.
 5. A method according to any one of claims 1 to4 and including the step of providing reinforcing between said mouldsprior to depositing of the concrete or other settable material.
 6. Amethod according to any one of claims 1 to 5 wherein saidinterconnecting means comprise elongated connectors and wherein saidpanels include apertures in said peripheral portions, and whereinopposite ends of said elongated connectors are passed through alignedsaid apertures in said overlapping portions of said panels tointerconnect said panels and said moulds.
 7. A method according to claim6 wherein at least some of said apertures carry flexible bushes orinserts and wherein said ends of said connectors are passed through saidflexible bushes or inserts.
 8. A method according to claim 6 whereinsaid ends of said elongated connectors are removed after curing of saidconcrete or other settable material.
 9. Apparatus for forming walls ofconcrete or other settable material, said apparatus including first andsecond moulds, each said mould having a mould face defined by aplurality of mould panels, each said mould panel having a mouldingsurface, the peripheral portions of adjacent said mould panelsoverlapping each other and said moulding surfaces being substantiallycoplanar to define mould faces of said first and second moulds, andinterconnecting means holding said moulds at a desired spacing to definea mould cavity therebetween, said interconnecting means extendingthrough said overlapping peripheral portions of said mould panels tointerconnect at least adjacent side by side said mould panels 10.Apparatus according to claim 9 wherein said panels are interconnected bysaid interconnecting means in such as manner as to permit limitedmovement of said mould panels relative to each other in a directionparallel to said mould face.
 11. Apparatus according to claim 10 andincluding flexible or elastic means between mating edges of said mouldpanels to accommodate said limited movement between said mould panels.12. Apparatus according to any one of claims 9 to 11 wherein one or bothsaid moulds are supported in an upright position by at least one supportpost or frame, said mould or moulds being connected to said at least onesupport post or frame by said interconnecting means.
 13. Apparatusaccording to claim 12 wherein a plurality of support posts or frames areprovided and adjacent support posts or frames are interconnected byelongated spanning members which hold said posts or frames at a fixedspacing relative to each other.
 14. Apparatus according to any one ofclaims 9 to 13 wherein said peripheral portions of said mould panels areprovided with a plurality of apertures therethrough, apertures inadjacent said panels being aligned when said peripheral portions thereofoverlap and wherein said interconnecting means comprise elongatedconnectors which extend into opposite aligned apertures in oppositemould panels.
 15. Apparatus according to claim 14 wherein said elongatedconnectors are provided with flanges which abut the mould faces to holdsaid moulds at a desired spacing.
 16. Apparatus according to claim 15wherein said elongated connectors have ends which project through saidaligned apertures and wherein stop means engaged with said pin ends holdsaid panels to said elongated connectors.
 17. Apparatus according toclaim 16 wherein said pin ends include enlarged diameter bosses adjacentsaid flanges for location in said apertures, said bosses being of alength slightly greater than the width of joined panels.
 18. Apparatusaccording to claim 17 wherein said ends of said elongated connectors areseparable from the remainder of the elongated connectors adjacent saidflanges to leave a surface substantially flush with the outer surface ofthe wall being moulded.
 19. Apparatus according to claim 18 wherein saidelongated connectors are necked or undercut adjacent said flanges tofacilitate separation of said ends
 20. Apparatus according to claim 14wherein said each said connector comprise an elongated sleeve having asaid flange at opposite ends thereof and an elongated pin removablyreceived within said sleeve, said pin projecting beyond said flanges todefine said ends of said connectors.
 21. Apparatus according to claim 20and including bungs receivable in opposite ends of said sleeve uponremoval of said elongate pin to close said ends of said sleeve adjacentto said flanges.
 22. Apparatus according to claim 20 wherein saidelongated pin comprises an inner pin member and an outer tubular sleevemember surrounding said inner pin member and being of a length greaterthan said elongated sleeves to define bosses for location in saidaligned apertures.
 23. Apparatus according to any one of claims 16 to 22wherein said ends include at least one slot for receiving a stop membertherethrough defining said stop means.
 24. Apparatus according to claim23 wherein said stop member is of a wedge-shaped or taperingconfiguration for wedging into said slot.
 25. Apparatus according toclaim 23 wherein a pair of spaced slots are provided in at least one endto locate said stop members at different positions in said ends. 26.Apparatus according to any one of claims 16 to 18 wherein said ends haveone or more flats for cooperation with a socket of a tool and wherebythe tool may be twisted or rotated to effect separation of said ends ofsaid elongated connectors.
 27. Apparatus according to any one of claims16 to 22 wherein said ends are threaded and wherein said stop meanscomprise nuts threadably engageable with said ends.
 28. Apparatusaccording to any one of claims 15 to 27 wherein said stop means whenengaged with said ends allow said panels to move longitudinally of saidmould faces and transversely of said connectors.
 29. Apparatus accordingto any one of claims 14 to 28 wherein at least some of said apertures insaid panels are provided with a flexible bush or insert to receive saidends of said elongated connectors.
 30. Apparatus according to any one ofclaims 14 to 29 wherein said panels include outer flanges which overlapand wherein said apertures in the panels are provided in said flanges,said apertures in adjacent panels being aligned when the flanges overlapeach other.
 31. Apparatus according to any one of claims 9 to 30 whereinsaid panels are substantially rectangular and wherein the corners of theflanges of at least some of the panels are truncated at 45 degrees toallow cooperation which adjacent diagonally arranged panels. 32.Apparatus according to any one of claims 9 to 30 wherein said panels areof a curved configuration for forming moulds of curved configuration toform curved walls.
 33. Apparatus according to any one of claims 9 to 32and including reinforcing between said moulds, said reinforcingincluding a plurality of vertical reinforcing members.
 34. Apparatusaccording to claim 33 wherein said vertical reinforcing members aresecured to upwardly projecting starter bars and wherein resilientsleeves are provided over the starter bars to allow for independentexpansion movement of the concrete wall.
 35. Apparatus according toclaim 33 wherein said wall is erected on a floor slab and wherein mountsare provided in said floor slab for supporting said vertical reinforcingmembers, said mounts allowing limited movement of said reinforcing andthus said wall relative to said floor slab.
 36. Apparatus according toclaim 35 wherein each said mount comprises a base member which isanchored in the slab and a coupling member which is supported forlimited horizontal and vertical movement relative to the base member.37. Apparatus according to claim 36 wherein said coupling memberincludes a plate carrying a socket for engagement by a verticalreinforcing member and wherein said base member captures said plate. 38.Apparatus according to claim 37 wherein said base member includes firstand second plates located above and below said coupling plate. 39.Apparatus according to claim 37 or claim 38 wherein said socket projectsabove said slab and a cover seals the socket to said base member toprevent ingress of concrete or other settable material into said mount.40. Apparatus according to any one of claims 37 to 39 wherein resilientpads are provided to limit movement of said coupling member. 41.Apparatus according to any one of claims 9 to 40 wherein said wall isformed directly on a floor slab.
 42. Apparatus according to claim 41 andincluding external clamp means for holding said moulds to a floor. 43.Apparatus according to claims 9 to 41 wherein said wall is erected on afloor slab and including an impervious membrane or layer which isapplied said floor slab prior to pouring of the concrete or othersettable material to allow the formed wall to expand independently ofthe slab.
 44. Apparatus according to claim 41 or claim 43 and includinga door frame for defining a door opening through a said wall, said doorframe being located between opposite said moulds prior to pouring ofconcrete or other settable material into said mould cavity. 45.Apparatus according to claim 44 and including a reinforcing link locatedwithin said slab and extending between said door opening and into saidmould cavity on opposite sides of said door opening.
 46. Apparatusaccording to any one of claims 9 to 45 and including first and secondaligned frames positioned adjacent opposite said moulds and there beingprovided infill panels extending between said first and second framesand defining a window opening.
 47. Apparatus according to claim 46wherein diagonally arranged mould panels defining corners of said widowopening are mitred to mate at two mutually perpendicular edges, saidpanels having mating flanges for overlapping by a further mould panelwhich defines with said corner mould panels part of a said mould face.48. Apparatus according to any one of claims 9 to 45 and including aframe for defining a window opening, said frame being located betweenopposite side moulds prior to pouring of concrete or other settablematerial into said mould cavity.
 49. Apparatus according to claim 48wherein said frame includes a sill defining member, said sill definingmember having one or more closable air expulsion openings therein topermit expulsion of air during moulding.
 50. Apparatus according toclaim 49 wherein said sill defining member is provided with one or moreaccess openings and there being provided means for closing saidopenings.
 51. Apparatus according to any one of claims 9 to 50 andincluding an expansion joint incorporated into said moulds to separatesaid moulds into adjacent mould sections, said expansion joint includingcomplementary end members secured to adjacent mould sections and havingcooperable configurations to maintain said mould sections inlongitudinal alignment.
 52. Apparatus according to claim 51 andincluding a resiliently compressible material between said end members.53. Apparatus according to claim 51 or 52 and including means spanningsaid adjacent mould sections at said expansion joint for limitinglongitudinal movement of said mould sections away from each other. 54.Apparatus according to claim 9 and including an end member secured to afree end of said moulds to define a moulded said wall as a buttresswall.
 55. Apparatus according to claim 9 and including a pair of angledcorner mould panels joined to and aligned with the respective saidmoulds by bridging members to define a corner of a moulded wall. 56.Apparatus according to claim 9 and including T-junction defining mouldpanels comprising a first planar mould panel and a pair of oppositeright angled mould panels, said planar mould panel being aligned withand secured to one said mould and said angled mould panels being alignedwith and secured to the other said mould to define walls extending atright angles to each other.
 57. Apparatus according to claim 41 or claim43 and including a conduit spanning the junction between said floor slaband wall cavity, opposite ends of said conduit being connected toflexible conduits for carrying cables or pipes.
 58. Apparatus accordingto any one of claims 9 to 57 and including one or more further curvedmoulding members or inserts adapted for location between said moulds forforming an arch in a formed said wall.
 59. Apparatus according to anyone of claims 9 to 58 and including one or more further moulding membersor inserts adapted for location between said moulds to form a gable in aformed said wall.
 60. A method of erecting a mould assembly forconstructing a wall of concrete or other settable material, said methodincluding the steps of providing first and second moulds, each saidmould comprising a plurality of mould panels, each said mould panelhaving a moulding surface, arranging said mould panels relative to eachother such that peripheral portions of adjacent said mould panelsoverlap and said moulding surfaces are substantially coplanar to definemould faces of said first and second moulds, providing interconnectingmeans for holding said moulds at a desired spacing to define a mouldcavity therebetween, said interconnecting means extending through saidoverlapping portions of said mould panels to interconnect at leastadjacent side by side mould panels in each said mould.
 61. The method ofclaim 60 wherein said interconnection means interconnects said mouldsand mould panels in such a manner as to prevent movement of said mouldfaces transversely away from each other but permitting limited movementof said panels longitudinally relative to each other.
 62. A methodaccording to claim 61 and including the step of providing flexible orelastic means between mating edges of the mould panels to accommodatesaid limited longitudinal movement thereof.
 63. A method according toany one of claims 60 to 62 wherein said interconnecting means compriseelongated connectors and wherein said overlapping peripheral portions ofsaid panels include aligned apertures, and wherein opposite ends of saidelongated connectors are passed through said aligned said apertures tointerconnect said panels and said moulds.
 64. A method according toclaim 63 and including the step of providing at least one support framefor supporting one or both said moulds in an upright position, andwherein at least one said end of a said elongated connector is passedthrough an aperture in said support frame to secure said mould to saidsupport frames.
 65. A method of erecting a mould assembly forconstructing a wall of concrete or other settable material, said methodincluding the steps of arranging at least one pair of mould panels in adesired spacing to define a mould cavity therebetween, said mould panelshaving apertures therein, the apertures in the respective mould panelsbeing transversely aligned with each other, providing flexible elementswithin said apertures, providing interconnecting means between saidmould panels for holding said mould panels at said desired spacing, saidinterconnecting means extending through said flexible elements andapertures in said spaced mould panels, whereby to permit limitedlongitudinal movement of said mould panels relative to saidinterconnecting means.
 66. A method according to claim 65 and includingthe step of arranging a plurality of mould panels in an edge-to-edgemating relationship and providing flexible or elastic means betweenmating edges of the mould panels to accommodate said limitedlongitudinal movement thereof.
 67. A method according to claim 66 andincluding the step of providing a plurality of upright support means forsupporting said mould panels in an upright attitude, and securing saidinterconnecting means to said support means on at least one side of saidmould panels.
 68. A method according to claim 67 and including the stepof providing elongated spanning members for spanning said uprightsupport means and interconnecting said elongated members to said uprightsupport members to form a support grid for said panels.
 69. A methodaccording to claim 68 and including the step of securing a plurality ofelongated upright members to said upper and lower elongated spanningmembers between said upright support means.
 70. A method according toclaim 69 and including the step of securing said elongated spanningmembers to said upright support means and said elongated upright membersto said upper and lower spanning members with said interconnectingmeans.